High-power electrical quick connector

Abstract

A quick connector assembly for high power electrical applications and method of manufacturing a high-power quick connector assembly are disclosed. The quick connector assembly has a first connector and a second connector constructed to form an electrical connection that can be quickly coupled and decoupled. The first connector has a collar portion connectable to a welding cable and a stem portion having a shank section and a threaded section. The second connector has a recess constructed to receive the stem portion of the first connector and electrically engage both the shank portion and the threaded portion of the first connector.

1 . A high-power quick connector assembly comprising: 
 a first connector having a stem portion and a collar portion connectable to a welding cable, the stem portion having a shank end and a threaded end;    a second connector having a recess formed therein, the recess constructed to receive the stem portion of the first connector and engage the shank end and the threaded end; and    wherein the stem portion of the first connector further comprises a channel formed therein.    
   
   
       2 . The high-power quick connector assembly of  claim 1  wherein the second connector further comprises a pin extending into the recess of the second connector and constructed to engage the channel formed in the stem portion of the first connector.  
   
   
       3 . The high-power quick connector assembly of  claim 1  wherein the channel extends in a first direction generally axially along the stem portion and in a second direction generally circumferentially about the stem portion of the first connector.  
   
   
       4 . A quick connector assembly for a welding-type device comprising: 
 a cable adapter connectable to a welding cable and having a cable end and a welding device end; and    a device adapter constructed to engage the welding device end of the cable adapter, the device adapter comprising: 
 a body having a first end, a second end, and an annular groove formed on an exterior surface of the body of the device adapter between the first and second ends;  
 a recess extending into the body from the first end;  
 a threaded section formed in the recess proximate the first end; and  
 a smooth section formed in the recess between the threaded section and the second end.  
   
   
   
       5 . The quick connector assembly of  claim 4  further comprising a pin extending into the recess of the device adapter generally between the threaded section and the smooth section.  
   
   
       6 . The quick connector assembly of  claim 4  wherein welding device end of the cable adapter further comprises an unthreaded portion having a groove extending from an end of the cable adapter to a threaded portion of the cable adapter.  
   
   
       7 . The quick connector assembly of  claim 4  wherein the cable adapter further comprises a groove formed in the unthreaded portion, the groove having an axial section extending generally axially along the unthreaded portion and a circumferential section extending generally circumferentially about the unthreaded portion.  
   
   
       8 . The quick connector assembly of  claim 7  wherein the circumferential section of the groove is positioned between the unthreaded portion and the threaded portion.  
   
   
       9 . A method of manufacturing a high-power quick connector assembly comprising: 
 forming a receiver having a first internal profile and a second internal profile; and    forming a plug having a first external profile constructed to pass the second internal profile of the receiver and engage the first internal profile of the receiver, and a second external profile constructed to engage the second internal profile of the receiver upon rotation therebetween.    
   
   
       10 . The method of  claim 9  further comprising providing at least one of a tellurium copper material, a sulfur copper material, and a chromium copper material for forming at least one of the receiver and plug.  
   
   
       11 . The method of  claim 9  further comprising forming a plurality of threads about the second internal profile of the receiver and the second external profile of the plug.  
   
   
       12 . The method of  claim 11  further comprising forming a groove across the plurality of threads of the receiver.  
   
   
       13 . The method of  claim 9  further comprising forming an annular groove about an outer surface of the receiver.  
   
   
       14 . The method of  claim 9  further comprising forming a recess in the plug for receiving a weld cable at an end generally opposite the first external profile.  
   
   
       15 . The method of  claim 14  further comprising forming a plurality of threaded openings through the plug into the recess.  
   
   
       16 . The method of  claim 9  further comprising forming a plurality of threads about an internal surface and forming a plurality of threads about an external surface of the receiver about an end generally opposite the second internal profile.  
   
   
       17 . The method of  claim 9  further comprising attaching the receiver to a power source capable of generating a power signal suitable for welding.  
   
   
       18 . The method of  claim 9  further comprising forming a rib extending from the first external profile of the plug.  
   
   
       19 . The method of  claim 18  wherein a majority of the second internal profile of the receiver has a diameter that is less than a diameter of the rib extending from the first external profile of the plug.  
   
   
       20 . The method of  claim 9  further comprising forming a groove in the first external profile of the plug.  
   
   
       21 . The method of  claim 9  further comprising positioning a pin in the receiver generally between the first internal profile and the second internal profile.  
   
   
       22 . The method of  claim 9  further comprising locking the plug to the receiver in less than 100 degrees of rotation between the plug and the receiver.  
   
   
       23 . A connector assembly comprising: 
 a cable connector connectable to a weld cable;    an output connector electrically connectable to a power source configured to generate a power signal suitable for welding applications, the output connector including a locking pin constructed to engage a locking groove formed in the cable connector; and    wherein at least one of the cable connector and output connector are constructed from at least one of a tellurium copper material, a sulfur copper material, and a chromium copper material.    
   
   
       24 . The connector assembly of  claim 23  wherein the locking groove includes a first portion that extends axially along the cable connector and a second portion that extends circumferentially about the cable connector.  
   
   
       25 . The connector assembly of  claim 23  wherein the cable connector further comprises a threaded section having an outer diameter that is greater than a diameter of a portion of the cable connector having the groove formed therein.